DismantlingGuide · 2013-06-25 · PleasecontactfollowingnumberiftheLi-ionbatterycannotbedischarged. • NissanEVCustomerSupport:1-877-664-2738(HoursofoperationareMonday-Friday7am

®

2012 LEAF

Dismantling Guide

1

Foreword

This manual describes dismantling operations and related warnings and cautions for this vehicle.This vehicle is an electrically driven car equipped with a high voltage battery pack. Failure to follow

recommended practices during dismantling will cause death or serious personal injury.

Please read this manual in advance in order to understand the features of this vehicle and to help you dealwith dismantling operations involving this vehicle. Follow the procedures in order to help assure asuccessful dismantling operation.

NISSAN EMERGENCY CONTACT INFORMATION• Nissan EV Customer Support: 1-877-664-2738 (Hours of operation are Monday-Friday 7am -

7pm, Saturday 8am - 4:30pm Central time zone)• Nissan Consumer Affairs: 1-800-647-7261 (US) or 1-800-387-0122 (Canada) (Hours of

operation are 8am - 5pm (Monday-Friday) Eastern, Central and Pacific time zones)

IMPORTANT INFORMATION ABOUT THIS MANUAL

You may see various symbols in this manual. They have the following meanings:

This symbol is used to inform you of an operation which will result in death or serious personal injury ifinstructions are not followed.

Example: Touching high voltage components without using the appropriate protective equipment will resultin electrocution.

This symbol is used to inform you of an operation which may cause death or serious personal injury ifinstructions are not followed.

This symbol is used to inform you of an operation which may cause personal injury or component damage ifinstructions are not followed.

Please note that there may be differences between this manual and the vehicle specification due tospecification changes. In such a case, follow this manual.

2

Table of Contents

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

NISSAN EMERGENCY CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

IMPORTANT INFORMATION ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. ABOUT THE NISSAN LEAF® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1-1 LEAF IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1-1.1. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1-1.2. INTERIOR COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-2 VEHICLE IDENTIFICATION NUMBER (VIN) LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1-3 WARNING AND INDICATOR LAMP INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2. BASIC HIGH VOLTAGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2-1 HIGH VOLTAGE-RELATED AND 12V-RELATED COMPONENT LOCATIONS ANDDESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2-1.1. LI-ION BATTERY PACK SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-2 HIGH VOLTAGE SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-2.1. WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-3 HIGH VOLTAGE CIRCUIT SHUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2-4 PREVENTING ELECTRICAL SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3. PREPARATION FOR DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3-1 DISCHARGING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3-2 PREPARATION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3-3 HIGH VOLTAGE SYSTEM SHUT-DOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3-3.1. REMOVING THE CHARGE CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3-3.2. INDICATIONS THE HIGH VOLTAGE SYSTEM IS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3-3.3. POWERING DOWN THE HIGH VOLTAGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3-3.4. PRIMARY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3-3.5. ALTERNATE PROCEDURE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3-3.6. ALTERNATE PROCEDURE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3-4 CUTTING THE VEHICLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3-4.1. SRS AIR BAG SYSTEM COMPONENTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3-4.2. VEHICLE CUT SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3-4.3. WATER SUBMERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3-4.4. VEHICLE FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3-5 LI-ION BATTERY DAMAGE AND FLUID LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4. JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4-1 JUMP STARTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3

4-2 ELECTRIC PARKING BRAKE MECHANICAL RELEASE PROCEDURE . . . . . . . . . . . . . . . . . . 30

4-3 P (PARK) POSITION RELEASE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4-3.1. RESET PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4-4 STORING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5. DISMANTLING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5-1 PRECAUTIONS FOR HANDLING HIGH VOLTAGE LITHIUM ION (LI-ION) BATTERY . . . . . . . . 35

5-2 PPE (PERSONAL PROTECTIVE EQUIPMENT) AND INSULATED TOOLS . . . . . . . . . . . . . . . . 36

5-2.1. PPE (PERSONAL PROTECTIVE EQUIPMENT) PROTECTIVE WEAR CONTROL . . . . . 36

5-2.2. DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5-2.3. INSULATED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5-3 LITHIUM-ION (LI-ION) BATTERY PACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5-3.1. EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5-3.2. REMOVAL PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5-4 RECOVERY/RECYCLING OF THE LI-ION HIGH VOLTAGE BATTERY . . . . . . . . . . . . . . . . . . . 41

4

1. About The Nissan LEAF®

This vehicle uses two types of batteries. One is a 12V battery that is the same as the battery in vehiclespowered by internal combustion engines, and the other is the Lithium-ion (Li-ion) battery (high voltage) forthe traction motor which propels the vehicle. The Li-ion battery is encased in steel and mounted underneaththe vehicle.

The vehicle must be plugged-in in order for the Li-ion battery to be recharged. Additionally, the vehiclesystem can recharge the Li-ion battery by converting driving force into electricity while the vehicle isdecelerating or being driven downhill. This is called regenerative charging. This vehicle is considered to bean environmentally friendly vehicle because it does not emit exhaust gases.

5

1-1 LEAF Identification

1-1.1 Exterior

The specific exterior identification features are indicated as follows:

No tail pipe

LEAF identification from underside:

1. Plastic shields cover entire underside.

2. No exhaust system components.

AAYIA0026GB

6

1-1.2 Interior Component Location

Interior components referenced in this manual are as follows:

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7

1-2 Vehicle Identification Number (VIN) Layout

The vehicle identification number can be located as follows:

Example VIN : JN1A Z0CP3BT000001

The LEAF is identified by the 5 th alphanumeric character: Z

Z = Electric vehicle

1. VIN plate (visible through windshield) 2. Vehicle certification plate (lower center pillar)

1-3 Warning and Indicator Lamp Information

The following warning and indicator lamps are located in the instrument cluster.

Lamp Name Icon Description

READY Indicator This lamp is on when the EV system is powered up and thevehicle is ready to drive.

EV System Warning Lamp *1 • Malfunction has occurred in the EV system and/or• Emergency shut-off system has been activated. The shut-off

system activates in the following conditions:– Front and side collisions in which the air bags are

deployed.– Certain rear collisions.– Certain EV system malfunctions.

Master Warning Lamp (RED) This lamp is on when another red warning lamp is displayed inthe instrument cluster or a warning is displayed on the dot matrixLCD.

Master Warning Lamp (YEL-LOW)

This lamp is on when:• Li-ion battery is getting low on charge.• A yellow warning lamp is displayed in the instrument cluster

or a message is displayed on the dot matrix LCD.

*1: When this lamp is ON, the ready lamp will turn OFF.

1

2

AAYIA0090ZZ

8

2. Basic High Voltage Information

2-1 High Voltage-Related and 12V-Related Component Locations andDescriptions

=

3

7

10

11

8

5

46

19

112

12

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9

NOTE:

Components with white number in black background are high voltage components.

No. Component Location Description

a Traction Motor Under hood Converts three-phase AC power to drivepower (torque) which propels the vehicle.

b DC/DC Converter– High voltagejunction box

Under hood This component includes a DC/DC converterand high voltage junction box (J/B). The junc-tion box provides electric power from the Li-ionbattery to all high voltage parts of the vehicle.The DC/DC converter reduces the voltage ofthe Li-ion battery to provide power to the 12Vbattery in order to operate the vehicle’s electriccomponents (headlights, audio system, etc.).

c Inverter Under hood Converts the DC power stored in the Li-ionbattery to three-phase AC power and controlsmotor torque (revolution) by regulating themotor current.

d Electric air condi-tioner compressor

Under hood Air conditioner compressor

e Cabin heater Under hood This is the electric heat source for the cabinheater. It heats the interior of the vehicle.

f Charge port Under hood Connecting port for EVSE (Electric VehicleSupply Equipment). Two ports are available:Normal charge and quick charge (if soequipped).

g 12V Battery Under hood A lead-acid battery that supplies power to thelow voltage devices.

h Li-ion (Lithium ion)battery

Undercarriage Stores and outputs DC power (Maximum volt-age 400V) needed to propel the vehicle.

i High voltagecables

Undercarriage andUnder hood

Orange-colored power cables carry high volt-age current between each of the high voltagecomponents.

j High voltage bat-tery service dis-connect

Rear seat floor Isolates the battery from the rest of the highvoltage electrical system.

k On Board Charger Cargo area (This unitis installed behind atrim panel to preventaccess)

Converts single-phase AC power from a homepower outlet to DC power and increases the volt-age in order to charge the Li-ion battery.

l Brake power supplybackup unit

Cargo area (This unitis installed behind atrim panel to preventaccess)

Power supply backup unit for the brake system. Itsupplies power to the brake system if a malfunc-tion occurs in the 12V battery.

10

2-1.1 Li-ion Battery Pack Specifications

Li-ion battery voltage 403.2V

Number of Li-ion battery modules in the pack 48

Li-ion battery dimensions 61.8 x 46.8 x 10.4 in. (1570.5 x 1188 x 264.9 mm)

Li-ion battery weight 648 lbs (294 kg)

2-2 High Voltage Safety Measures

Circuit insulation The high voltage positive (+) and negative (-) circuits are insulatedfrom the metal chassis.

Reducing the risk of electrocution The high voltage components and harnesses have insulated cases ororange-colored coverings which provide insulation and easy identifica-tion.

The high voltage battery case is electrically connected to the vehicleground. This connection helps protect the vehicle occupants andvehicle dismantlers from high voltage electrical shock.

Identification The high voltage components are labeled “WARNING” similar to labelshown below. All high voltage harnesses are coated in orange.

2-2.1 Warning Label

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11

2-3 High Voltage Circuit Shut-Off System

The high voltage can be shut off by the following methods:

Service plug Positioned in the center area of the Li-ion battery, this shuts off output highvoltage when manually removed.

System main relay Controlled by the power switch, this relay, which is controlled by the 12Vsystem, shuts off the high voltage from the Li-ion battery.

Emergency shut-off sys-tem

In the case of a collision (front and side collisions in which the air bags aredeployed, certain rear collisions) or certain system malfunctions this systemmay shut off the high voltage from the Li-ion battery.

Charging connector Some of the high voltage components are activated during charging. Removethe charging connector to deactivate these components.

2-4 Preventing Electrical Shock

1. If it is necessary to touch any of the high voltage harnesses or components, you must alwayswear appropriate PPE (refer to 3-2 Preparation Items) and shut off the high voltage system byreferring to 3-3 High Voltage System Shut-Down Procedure.

2. To avoid the risk of electrocution, do not touch the inside of the Li-ion battery unless appropriatePPE is worn even after shutting off the high voltage system. The Li-ion battery maintains chargeeven though the high voltage system is shut down.

3. Cover any damaged high voltage components with insulated tape.

12

3. Preparation for Dismantling

• Failure to properly shut down the high voltage electrical system before the

Dismantling Procedures are performed will result in serious injury or death from

electrical shock. To prevent serious injury or death, DO NOT touch high voltage

harnesses or components without always wearing appropriate PPE.

• If it is necessary to touch any of the high voltage harnesses or components you must

always wear appropriate PPE to avoid electrical shock. Shut down the high voltage

system by following the steps outlined in 3-3 High Voltage System Shut-Down Proce-

dure. Wait at least ten (10) minutes for complete discharge of the high voltage capacitor

after the high voltage system has been shut down.

• NEVER assume the LEAF is shut OFF simply because it is quiet.

• If it becomes necessary for the dismantler to leave the vehicle, place a “DANGER” sign

(for example, refer to 4-4 Storing the Vehicle) on the vehicle to alert other people that the

vehicle contains a high voltage battery.

• If the READY indicator, charging indicator or air conditioning remote timer

indicator are ON the high voltage system is active.

• If possible, be sure to verify that the READY indicator on the instrument cluster

is OFF and the high voltage system is stopped.

3-1 Discharging Procedures

Do not perform this procedure if the battery is damaged. If you are unsure of battery

damage, use extreme caution and wear appropriate PPE.

Li-ion battery discharging must take place before dismantling. Sufficient discharging can be achieved byfollowing these steps.

1. Place the selector lever into the Park (P) position2. Apply the parking brake.3. Set wheel chocks to ensure the vehicle is completely stopped.

13

4. Apply foot brake and press the ignition switch to turn the system ON. Confirm READYindicator in instrument cluster turns ON.

5. Check Li-ion battery available charge gauge:

a. If remaining energy (1) shows higher than half full (7 of 12 gauge lines lit up), continue tonext step.

b. If remaining energy (2) shows lower than half full (6 of 12 gauge lines lit up), discharging isnot needed.

6. Turn ON electric devices such as headlamps, cabin heater (set to the highest temperature andmaximum fan speed; do not use AUTO A/C setting), navigation system and rear window defoggerto discharge the Li-ion battery. Allow approximately 30 minutes for each line on the availablecharge gauge to drop. Discharge is complete when the available charge gauge drops to lowerthan half full (6 of 12 gauge lines lit up).

7. Press the power switch to turn the system OFF.

LOCK Acc

(OFF)

ON

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0

1

POWER

Brake

P A

120miles

0.0miles

MPH

PM

F

miles

1 2

AAYIA0037GB

14

Please contact following number if the Li-ion battery cannot be discharged.• Nissan EV Customer Support: 1-877-664-2738 (Hours of operation are Monday - Friday 7am -

7pm, Saturday 8am - 4:30pm Central time zone)• Nissan Consumer Affairs: 1-800-647-7261 (US) or 1-800-387-0122 (Canada) (Hours of

operation are 8am - 5pm (Monday - Friday) Eastern, Central and Pacific time zones)

3-2 Preparation Items

Preparation Items Specification Purpose

PPE (personal protectiveequipment):

Insulated glovesUp to 1,000V

For protection from high voltage electri-cal shock

Insulated shoes

–

Safety shield

–

Wrenches

Size:10mm

To remove the service plug accesscover bolts.To remove the 12V battery terminal bolt.

Solvent resistant protectiongloves

Solvent resistant protectionshoes

– To utilize in the event of a Li-ion batteryelectrolytic solution leak.

–

Absorbent pad The same pad used for internal com-bustion engine fluids can be used.

To absorb any Li-ion battery electrolyticsolution leakage.

Standard fire fightingequipment

Standard fire fighting equipment

Depending on type of fire (vehicle orbattery) use standard fire fightingequipment (water or extinguisher).

To extinguish a fire.

Insulated tape Insulating

To cover any damaged harnesses toprotect from and prevent electricalshock. Tape should cover all bare ordamaged wire.

15

3-3 High Voltage System Shut-Down Procedure

Any of the following procedures can shut down the high voltage system. The dismantling operation can onlybegin after shutting down the high voltage system. If the vehicle is heavily damaged, for example the Li-ionbattery is deformed, broken or cracked, appropriate PPE must always be used and the Li-ion battery andhigh voltage components must not be touched.

• Failure to properly shut down the high voltage system before the dismantling

procedures are performed will result in serious injury or death from electrical shock.

To prevent serious injury or death, DO NOT touch high voltage harnesses or

components without always wearing appropriate PPE.

• When contact with high voltage components or high voltage harnesses is

unavoidable, or when there is risk of such contact, you must always wear appropriate

PPE.

16

• If the charge connector is connected to the vehicle, remove it. Refer to 3-3.1 Removing

the Charge Connector.

• The vehicle contains parts that contain powerful magnets. If a person who is wearing

a pacemaker or other medical device is close to these parts, the medical device may be

affected by the magnets. Such persons must not perform work on the vehicle.

• Be sure to verify that the READY indicator is off and the high voltage system is

stopped.

• There is a possibility of remaining high voltage in the air conditioning system. If the

READY indicator is turned OFF and the air conditioning remote timer indicator is

turned ON the high voltage system is active. Please ensure that the air conditioning

remote timer indicator is turned OFF and the air conditioning system is inactive.

• After the high voltage system is shut down, please wait at least ten (10) minutes for

complete discharge of the high voltage capacitor. While waiting, do not operate any vehicle

functions.

NOTE:

The high voltage full discharge takes ten (10) minutes, but after five (5) minutes the voltage

has dropped below 60V.

• After shutting down the high voltage system and removing the 12V battery negative (-)

terminal, wait at least three (3) minutes to discharge the air bag capacitor. Even though the

12V battery negative (-) is disconnected, the Supplemental Restraint System (SRS) air bag

maintains voltage at least three (3) minutes. During this time, there is a possibility of

sudden SRS air bag inflation due to harness short circuit or damage and it may cause

serious injuries.

• Always shut down the high voltage system before disconnecting the 12V battery. Not doing

so may result in serious injury or death from electrical shock.

• The 12V system will remain active even after the 12V battery negative (-) terminal is

removed while the high voltage system is active. The high voltage system is active during

any of the following conditions:

– air conditioning system remote timer indicator is turned ON

– charging indicator is turned ON

– READY indicator is turned ON

Refer to 1-1.2 Interior Component Location for location of these indicators.This is because

DC/DC converter will not shut down and power will be supplied to the 12V system and

high voltage system continuously.

17

3-3.1 Removing the Charge Connector

1. Press the lock release button/lever on the charge connector.

NOTE:

The quick charge connector is not equipped on all models.

2. Pull the charge connector to remove it.

3-3.2 Indications the High Voltage System is ON

1. If the charge indicator is ON, the high voltage system is active.

2. If the air conditioning remote timer indicator (located on the HVAC controller) is ON, the high

voltage system is active.

3. If the remote controlled climate control system is active, push the power switch to the ON

position. This will turn OFF the remote controlled climate control system.

NOTE:

Remote controlled climate control system is a feature that allows the vehicle owner

to activate the climate control system via telematics communication (cell phone,

personal computer, etc.). When this system is active, the air conditioning remote

timer indicator (located on the HVAC controller) is illuminated.

Before disconnecting the 12V battery terminal, if necessary, set the parking brake, lower the windows,

unlock the doors, and open the rear hatch as required. Once 12V battery is disconnected, power controls

will not operate.

3-3.3 Powering Down the High Voltage System

The high voltage system can be shut down with any 1 of the following procedures:

• Turn OFF the power switch and disconnect the 12V battery. Refer to 3-3.4 Primary Procedure.

• Remove the fuses for the high voltage control system and disconnect the 12V battery. Refer to

3-3.5 Alternate Procedure 1.

• Remove the service plug and disconnect the 12V battery. Refer to 3-3.6 Alternate Procedure 2.

Trickle Charge Connector Quick Charge Connector

AAYIA0033GB

18

3-3.4 Primary Procedure

1. Check the READY indicator status. If it is ON, the high voltage system is active.2. Place the selector lever in the Park (P) position.3. Press the power switch once to turn OFF the high

voltage system. Then verify whether the READYindicator is OFF.

4. If possible, keep the Nissan Intelligent Key® at least 5meters (16 feet) away from the vehicle.

NOTE:

This step is not necessary if the 12V system is

already disabled.

5. Disconnect the negative (-) 12V battery cable (1).Insulate the negative (-) battery cable terminal withinsulated tape.

NOTE:

: Arrow in illustration depicts vehicle front

direction.

6. Wait at least ten (10) minutes for complete discharge of the high voltage capacitor after thepower switch has been turned OFF.

7. Perform the dismantling operation.

3-3.5 Alternate Procedure 1

1. Open the hood.

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1

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19

2. Press and expand the pawls (A) on the sides of the fuse box and remove the fuse box (1) from itshousing.

NOTE:

: Arrow in illustration depicts vehicle front direction.

NOTE:

There is no separate fuse box cover. The bottom of the fuse box is also its cover.

3. Remove the following fuses:a. VCM IGN fuse (F15 VCM IGN 10A)b. F/S1 RLY Fuse (F24 F/S1 RLY 15A)c. VCM Fuse (F3 VCM 20A)

4. If you cannot identify the above fuses, remove all fuses in the fuse box.

A

1

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F24 F/S1 RLY 15A

(Blue)

F15 VCM IGN 10A

(Red)

F3 VCM 20A

(Yellow)

AAYIA0030GB

20

5. Disconnect the negative (-) 12V battery cable (1).Insulate the negative (-) battery cable terminal withinsulated tape.

NOTE:


direction.

6. Wait at least ten (10) minutes for complete discharge of the high voltage capacitor after the fuses

are pulled.


To avoid unintended reinstallation and risk of electrical shock and severe personal

injury or death, the dismantler should carry the fuses on his/her person and cover the fuse

box with insulated tape.

3-3.6 Alternate Procedure 2

• Do not remove the service plug without always wearing appropriate PPE to help

protect the dismantler from serious injury or death by electrical shock.

• Immediately cover the service plug socket with insulated tape. The Li-ion battery

retains high voltage power even when the service plug is removed. To avoid electric

shock, DO NOT touch the terminals inside the socket.

To avoid unintended reinstallation and risk of electrical shock and severe personal injury

or death, the dismantler should carry the service plug on his/her person while work is in

progress.

1. Locate the carpet flap (1) behind the center console onthe floor raised area. At the notched area (A) pull up onthe carpet flap (1).

NOTE:


direction.

1

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AAYIA0116ZZ

21

2. Remove the 10mm access cover bolt (A) and turn the 2plastic clips (B) and remove the cover (1).

NOTE:


direction.

3. Remove the service plug by pressing the locking tab (1) and rotating the handle (2) upward.

Using the handle, pull the service plug completely out of its socket.

4. Wait at least ten (10) minutes for complete discharge of the high voltage capacitor after the

service plug has been removed.

5. Open the hood.6. Disconnect the negative (-) 12V battery cable (1).

Insulate the negative (-) battery cable terminal withinsulated tape.

NOTE:


direction.


A 1

B

AAYIA0025GB

1 2

AAYIA0113ZZ

1

AAYIA0092ZZ

22

3-4 Cutting the Vehicle Body

• Do not cut into high voltage related areas to avoid severe personal injury or death.

• Do not cut into the Li-ion battery to avoid severe personal injury or death.

• When removing parts, DO NOT touch the high voltage parts or the insides of the

exposed orange-colored high voltage cables to avoid severe personal injury or death.

• To avoid unintended reinstallation and risk of electrical shock and severe personal injury

or death, the dismantler should carry the service plug on his/her person while work is in

progress.

• Do not cut air bag parts to avoid unintended deployment of the air bags and the risk of

severe personal injury or death.

If at least ten (10) minutes have passed since the dismantler shut down the high voltage system (refer to3-3 High Voltage System Shut-Down Procedure), then the dismantler can cut the vehicle except for theLi-ion battery.

DO NOT cut the Li-ion battery due to possible electrocution risk and electrolyte solution

leakage.

23

3-4.1 SRS Air Bag System Components Location

The SRS air bag system must not be cut as there is a risk of short circuit and unintentional deployment of

the SRS. However, the vehicle can be cut (except inflators) under the following conditions:

• The front, side and curtain air bags have deployed.

• At least three (3) minutes have passed after the 12V battery negative (-) cable has been

disconnected and the high voltage system has been shut down.

1. Crash zone sensor 2. Supplemental front-impact airbag modules

3. Front seat-mounted side-impactsupplemental air bag modules

4. Roof-mounted curtain side-impact supplemental air baginflators

5. Roof-mounted curtain side-impact supplemental air bagmodules

6. Front door satellite sensors

7. Lap outer pretensioner (driverside only)

8. Seat belt with pretensioner 9. Rear satellite sensors (locatedin lower B-pillar)

10. Air bag control unit (ACU)

11 2 3 4 5

6 7 8 9 10

AAYIA0095ZZ

24

3-4.2

Vehicle

CutSheet

Key

Emergency Contact: Nissan EV Customer Support: 1-877-664-2738

(Monday-Friday 7am-7pm, Saturday 8am-4:30pm Central Time) orNissan Consumer Affairs: 1-800-647-7261 (US) or

1-800-387-0122 (Canada) (Monday-Friday 8am-5pm Eastern, Central and Pacific Time Zones)

High voltage component or harness(Can be cut only after the high voltagesystem shut-down procedure has beencompleted.)

NEVER CUT- Li-ion battery

12V Battery

Never cut electrical

components/batteries

for any reason. Death or serious

personal injury will result.

Nissan North America, Version 1, March 2010

DANGER

PTC heater

Vehicle Bottom View

Brake power supply

back up unit

High voltage Li-ion batteryHigh voltage harness

12V battery

12V batteryTraction motor and

reduction gear

25

3-4.3 Water Submersion

Damage level of submerged vehicle may not be apparent. Handling a submerged

vehicle without appropriate PPE will result in serious injury or death from electrical shock.

• The power switch of the submerged vehicle must be turned OFF first, if possible. Then

the vehicle must be completely out of the water and drained to avoid electrical shock.

• Always wear appropriate PPE and remove/drain water before removing the service

plug when working on a vehicle after a fire or submersion to avoid electrical shock.

• If the vehicle is in the water, to avoid electrical shock do not touch the high voltage

components, harnesses or service plug.

3-4.4 Vehicle Fire

• Always utilize full PPE and self-contained breathing apparatus during fire fighting

operations. Smoke from a LEAF vehicle fire is similar to smoke from a conventional

vehicle fire.

• In the case of extinguishing a fire with water, large amounts of water from a fire hydrant

(if possible) must be used. DO NOT extinguish fire with a small amount of water.

In the event of a small fire, a Type ABC fire extinguisher may be used for an electrical fire

caused by wiring harnesses, electrical components, etc. or oil fire.

In case of vehicle fire, contact fire department immediately and extinguish the fire if possible. If you mustwalk away from the vehicle, notify an appropriate responder or a rescue person of the fact that the vehicle isan electric car and contains a high voltage system and warn all others.

26

3-5 Li-ion Battery Damage and Fluid LeaksIn cases of battery case breach or electrolyte leakage, contact the fire department immediately. If you mustwalk away from the vehicle, notify an appropriate responder of the fact that the vehicle is an electric car andcontains a high voltage system and warn all others.

Li-ion Battery Electrolyte Solution Characteristics:• Clear in color• Sweet odor• Similar viscosity to water• Skin irritant• Eye irritant – If contact with eyes, rinse with plenty of water and see a doctor immediately.• If electrolyte leak occurs, wear appropriate solvent resistant PPE and use a dry cloth to clean up the

spilled electrolyte. Be sure to adequately ventilate the area.• Highly flammable• Electrolyte liquid or fumes that have come into contact with water vapors in the air will create an

oxidized substance. This substance may irritate skin and eyes. In these cases, rinse with plenty ofwater and see a doctor immediately.

• Electrolyte fumes (when inhaled) can cause respiratory irritation and acute intoxication. Move tofresh air and wash mouth with water. See a doctor immediately.

• Since the Li-ion battery is made up of many small sealed battery modules, electrolyte solutionleakage should be minimal.

27

4. Jump Starting

To start the EV system with a booster battery, the instructions and precautions below must be followed.

If done incorrectly, jump starting can lead to a 12V battery explosion, resulting in severe

personal injury or death. It could also damage your vehicle.

Discharged 12V battery may cause the following issues:

• The instrument cluster cannot be displayed while the power switch is turned ON. The start-up

sound is not audible. (The electric car system cannot start.)

• The Li-ion battery cannot be charged.

• The vehicle cannot be shifted out of PARK normally.

• The electric parking brake cannot be either set or released normally.

• To avoid electrical shock, the high voltage Li-ion battery CANNOT be jump started.

• Explosive hydrogen gas is always present in the vicinity of the 12V battery. Keep all

sparks and flames away from the 12V battery.

• Do not allow battery fluid to come into contact with eyes, skin, clothing or painted

surfaces. Battery fluid is a corrosive sulfuric acid solution that can cause severe burns. If

the fluid comes into contact with anything, immediately flush the contacted area with

water.

• The booster battery must be rated at 12 volts. Use of an improperly rated battery can

damage the vehicle.

• Whenever working on or near a 12V battery, always wear suitable eye protectors (for

example, goggles or industrial safety spectacles) and remove rings, metal bands, or any

other jewelry. Do not lean over the 12V battery when jump starting.

• Do not attempt to jump start a frozen battery. It could explode and cause serious injury.

• LEAF is equipped with an automatic cooling fan. It could come on at any time. Keep

hands and other objects away from it.

• Always follow the jump starting instructions below. Failure to do so could result in

damage to the DC/DC converter and cause personal injury.

• Do not use LEAF to jump start another vehicle.

• Do not attempt to perform a jump start on the 12V battery at the same time that theLi-ion battery is being charged. Doing so may damage the vehicle or chargingequipment and could cause an injury.

28

4-1 Jump Starting Procedures

1. If the booster battery is in another vehicle (B), position the two vehicles (A and B) to bring their12V batteries into close proximity to each other.

DO NOT allow the two vehicles to touch.

2. If the LEAF electric parking brake is not applied and the selector lever is not in the P (Park)position, immobilize the vehicle with wheel chocks.

3. Switch off all unnecessary electrical systems (headlights, heater, air conditioner, etc.).4. Place the power switch in the OFF position (if possible).

If the 12V battery is discharged, the power switch cannot be moved from the OFF

position. Connect the jumper cables to the booster vehicle (B) before pushing

the power switch.

5. Remove the vent caps on the 12V battery (if so equipped). Cover the battery with a firmly wrungout moist cloth to reduce the hazard of an explosion.

6. Connect jumper cables in the sequence as illustrated (a→b→c→d).

• Always connect positive (+) to positive (+) and negative (-) to body ground (for example,as illustrated), not to the 12V battery.

• Make sure the jumper cables do not touch moving parts in the motor compartment andthat the cable clamps do not contact any other metal.

7. Start the engine of the booster vehicle (B).8. While the booster vehicle (B) engine is running, place the LEAF in READY mode.

If the system does not start right away, push the power switch to the OFF position and wait

at least 10 seconds before trying again.

9. After starting the EV system, carefully disconnect the negative cable and then the positive cable(d→c→b→a). Keep the EV system on for over twenty (20) minutes to charge the 12Vbattery.

10. Replace the vent caps (if so equipped). Be sure to properly dispose of the cloth used to coverthe vent holes because it may be contaminated with corrosive acid.

AAYIA0127ZZ

29

11. If necessary, connect the vehicle to a charging station or EVSE (Electric Vehicle SupplyEquipment) to charge the Li-ion battery. The vehicle cannot be driven unless the Li-ion battery ischarged.

NOTE:

If it is not possible to turn the LEAF system ON by following this procedure, contact a

NISSAN certified LEAF dealer immediately.

4-2 Electric Parking Brake Mechanical Release Procedure

If the electric parking brake cannot be released by operating the parking brake switch, the parking brake canbe mechanically released.

When releasing the electric parking brake mechanically, always confirm that the vehicle is

in the P (Park) position. Confirm that the vehicle is in the P (Park) position by checking

the shift indicator located near the selector lever or the dot matrix liquid crystal display. If

the vehicle cannot be placed in the Park position, contact a NISSAN certified LEAF

dealer. If the vehicle is in any position other than the P (Park) position, the vehicle may

unexpectedly move and may cause serious personal injury or death. If the vehicle cannot

be shifted into the P (Park) position, contact a NISSAN certified LEAF dealer.

• Always perform this procedure after the electric parking brake switch operationindicator turns off. If not, the system may operate unexpectedly and the tool used formechanical release may move suddenly. This may cause personal injury.

• To release the parking brake mechanically, turn the power switch to the OFF positionand then make sure that the parking brake switch operation indicator turns off.

• If the vehicle is driven with the electric parking brake applied, the electric parking brakecomponents may overheat and cause a deterioration in electric parking brakeeffectiveness and premature electric parking brake wear.

• The electric parking brake mechanical release tool should be used only to release theelectric parking brake in an emergency.

NOTE:

The electric parking brake mechanical release tool can only be used to release the electric

parking brake. It cannot be used to apply the electric parking brake.

The electric parking brake operation switch indicator may turn OFF 1 minute after the

power switch is placed in the OFF position. If the parking brake switch operation indicator

does not turn OFF, contact a NISSAN certified LEAF dealer.

To release the parking brake mechanically, perform the following procedures.

1. Confirm that the vehicle is in the P (Park) position.

(Confirm that the vehicle is in the P (Park) position by checking the shift indicator located near theselector lever or the dot matrix liquid crystal display. If the vehicle cannot be placed in the Parkposition, contact a NISSAN certified LEAF dealer.)

30

2. Check that the parking brake switch operation indicator does not illuminate.3. Place power switch in the OFF position.4. Open the rear hatch.5. Remove the electric parking brake mechanical release

tool from the tool set that is located in the cargo area.

6. Remove the luggage floor board from the cargo area.7. Remove the cap by turning it counterclockwise.

8. Insert the tool and turn it counterclockwise while pushingit in.

9. Continue to turn until it stops and then release. The toolwill then return to approximately the same position as itwas in before it was turned and release of the parkingbrake will be completed. Do not turn the tool beyond thepoint at which it stops. Doing so may result in damage.

10. Return the tool set and vehicle interior parts back to original location.

4-3 P (Park) Position Release Procedure

If you need to release the vehicle from the P (Park) position, proceed as follows. When power switch isturned OFF or 12V battery is low, LEAF automatically shifts to P position.

NOTE:

This procedure requires two (2) people.

1. To start the EV system with a booster battery, refer to 4. Jump Starting.2. Turn power switch ON by pushing the power switch 2 times without pressing brake pedal.3. Confirm parking brake is ON (indicator in electric parking brake switch will be ON).4. Place the selector lever in the N (Neutral) position.5. Close all doors and press the brake pedal.

AAYIA0123ZZ

AAYIA0125ZZ

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31

6. Remove the following 3 fuses:

• PBW MTR-1 20A (under hood fuse box behind 12V battery)• PBW MTR-2 20A (under hood fuse box behind 12V battery)• METER 1 10A (in the cabin fuse box)

Under Hood Fuse Box Location

10

10

1010

10

2020

10

PBW MTR-2 20A

PBW MTR-1 20A

AAYIA0094ZZ

32

Cabin Fuse Box Location

NOTE:

Insert a screwdriver wrapped with a protective cloth (A) into the slit (1). Pull to remove the fuse

box cover (2). Remove the fuse with the fuse puller (3).

7. Release the electrical parking brake.8. Turn the power switch OFF.9. Release brake pedal.

Be sure to firmly position wheel chocks when P (Park) position is manually released.

4-3.1 Reset Procedure

1. Install the 3 fuses removed previously.2. Turn the power switch ON and wait 5 seconds without pressing the brake pedal. Ensure selector

lever is in the N (neutral) position.3. If 12V battery is low voltage, please charge with battery charger.4. Turn the power switch OFF and wait 5 seconds.

UP

11

3

2

C

METER BAT 10A

AAYIA0029GB

33

4-4 Storing the Vehicle

If LEAF needs to be stored or left unattended, the high voltage system must be shut down by removing theservice plug (refer to 3–3.6 Alternate Procedure 2) and a sign put on the vehicle indicating it is an electricvehicle with high voltage dangers. For example:

AAYIA0020GB

34

5. Dismantling Information

Removal or repair of the high voltage battery requires special tools and specific training. NISSAN stronglyrecommends that only certified NISSAN dealer technicians perform these operations.

5-1 Precautions for Handling High Voltage Lithium ion (Li-ion) Battery

• Because LEAF contains a high voltage (Li-ion) battery, there is the risk of electric

shock, electric leakage, or similar accidents if the high voltage components or vehicle is

handled incorrectly. Be sure to follow the correct work procedures when performing

inspection and dismantling.

• The colors of the high voltage harnesses and connectors are all orange. Orange (High

Voltage( labels are applied to the Li-ion battery and other high voltage devices. Do not

touch the Li-ion battery or other high voltage devices without always wearing appropriate

PPE.

• Clearly identify the persons responsible for high voltage work and ensure that other

persons do not touch the vehicle. When not working, cover high voltage parts with an

insulating cover sheet and sign or similar item to prevent other persons from contacting

them.

• The high voltage battery retains high voltage at all times.

• Be sure to always wear appropriate PPE before beginning work on the high voltage

system.

• If it is necessary to touch any of the high voltage harnesses or components you must

always wear appropriate PPE and properly shut-down the high voltage system by

removing the service plug.

• Be sure to remove the service plug in order to shut-down the high voltage system

before performing inspection or dismantling of high voltage system harnesses and parts.

• Be sure to put the removed service plug in your pocket and carry it with you so

another person does not accidentally reinstall it while work is in progress.

• Immediately insulate disconnected high voltage connectors and terminals with

insulated tape.

• The vehicle contains parts that contain powerful magnets. If a person who is wearing

a pacemaker or other medical device is close to these parts, the medical device may be

affected by the magnets. Such persons must not perform work on the vehicle.

• Because this vehicle uses components that contain high voltage and powerful

magnetism, do not carry any metal products which may cause short circuits, or any

magnetic media (cash cards, credit cards, etc.) which may be damaged when working on

the vehicle.

• Keep removed Li-ion battery packs away from rain to avoid electric shock.

• If the vehicle is heavily damaged, for example the Li-ion battery is deformed, broken,

or cracked; appropriate PPE must always be used at all times to avoid electrical shock.

• Do not heat removed battery packs higher than 158° F (70° C).

35

There is the possibility of a malfunction occurring if the vehicle is changed to READY

status while the service plug is removed.

5-2 PPE (Personal Protective Equipment) and Insulated Tools

5-2.1 PPE (Personal Protective Equipment) Protective Wear Control

Perform an inspection of the PPE items before beginning work. Do not use any damaged PPE items.

5-2.2 Daily Inspection

This inspection is performed before and after use. The worker who will be using the items should performthe inspection and check for deterioration and damage.

• Insulated rubber gloves should be inspected for scratches, holes and tears. (Visual check and airleakage test)

• Insulated safety boots should be inspected for holes, damage, nails, metal pieces, wear or otherproblems on the soles. (Visual check)

• Insulated rubber sheet should be inspected for tears. (Visual check)

5-2.3 Insulated Tools

When performing work at locations where high voltage is applied (such as terminals), use insulated toolsmeeting 1,000V/300A specifications.

36

5-3 Lithium-ion (Li-ion) Battery Pack Removal

5-3.1 Exploded View

1. Bonding plate (Stamp No. 6) 2. Li-ion battery pack 3. Bonding plate (Stamp No. 4)4. Bonding plate (Stamp No. 2) 5. Battery under cover (center) 6. Battery under cover (front)7. Clip 8. Battery under cover (rear) 9. Battery mounting bracket LH10. Battery mounting bracket RH

1

2

3

4

5

6

7

7

7

7

8

3

1

9

10

AAYIA0096ZZ

37

5-3.2 Removal Procedure

1. Raise the vehicle and remove the battery under covers (front, center and rear).2. Disconnect the high voltage connector (A) from the

Li-ion battery.

Touching high voltage components without wearing

appropriate PPE will cause electrocution.

a. Follow procedure below to disconnect the high

voltage connector.

Cover battery side of high voltage connector with

insulated tape (A).

: Insulated tape

3. Disconnect the Li-ion battery vehicle communicationsconnector (A) while turning it counterclockwise.



AAAYIA0114ZZ

AAYIA0112ZZ

A

AAYIA0104ZZ

A

AAYIA0115ZZ

38

4. Remove the bonding plates (3 locations).

NOTE:

The bonding plate (1, 2 and 3) shape differs

depending on the location of installation.



5. Remove ONLY the Li-ion battery mounting bolts (A) (6bolts).

At this stage of disassembly, NEVER remove the 4 bolts

(B) shown in the illustration. These remaining 4 bolts

will retain the Li-ion battery to the vehicle body

while the lifter table can be set up in the next step.



6. Set the pallet (1) onto the lifter table (2).

• Align the pallet center mark (A) and the lifter centermark (B) (white line).



2

1

2

3

3

AAYIA0117ZZ

B

B

A

B

A

A

A

B

AAYIA0118ZZ

1

1

2

2

B

B

A

A

AAYIA0097ZZ

39

7. Set the pallet (1) under the Li-ion battery.



8. Remove the remaining 4 Li-ion battery mounting bolts(A).

Touching high voltage components without wearing appropriate PPE will cause

electrocution.

9. Carefully lower the pallet and remove the Li-ion battery(1) from the vehicle.



10. Be sure service plug socket and high voltage connector(battery side) are covered with insulated tape.

11. Dismantling the remainder of the LEAF may beperformed like conventional NISSAN vehicles once thehigh voltage system is properly shut down anddischarged.

1

AAYIA0119ZZ

A

B C

A

AAYIA0120ZZ

1

AAYIA0121ZZ

40

5-4 Recovery/Recycling of the Li-ion High Voltage Battery

The Li-ion high voltage battery is fully recyclable. For information regarding safe recovery and recycling ofthe high voltage battery, please contact the nearest NISSAN dealer. For assistance in finding yournearest dealer please call NISSAN Customer Assistance at:

• Nissan EV Customer Support: 1-877-664-2738 (Hours of operation are Monday-Friday 7am -7pm, Saturday 8am - 4:30pm Central time zone)

• Nissan Consumer Affairs: 1-800-647-7261 (US) or 1-800-387-0122 (Canada) (Hours ofoperation are 8am - 5pm (Monday-Friday) Eastern, Central and Pacific time zones)

41

© 2012 NISSAN NORTH AMERICA, INC.All rights reserved.This document may not be altered without the written permission of NISSAN NORTH AMERICA, INC.Pub. No. DG2E-1ZE0U2

42

Documents

DismantlingGuide · 2013-06-25 · PleasecontactfollowingnumberiftheLi-ionbatterycannotbedischarged. • NissanEVCustomerSupport:1-877-664-2738(HoursofoperationareMonday-Friday7am